Installation Instructions LamboStyleDoors (The instruction are to be used as a reference. Please repeat for both doors) Mercedes C-Class Sport coupé type W203 Part number 500 25 009 Pre installation check list: - Vehicle must be accident free - Vehicle must have inner fender cover - Front fender removed - Battery disconnected - Double check vehicles data with TUV certificate Preparations: (Disassemble parts according to vehicle manufacturer specifications) 1. Disassemble the door stopper. 2. Disconnect the cable connector between chassis and door 3. Disassemble the door. 4. Modify the fender 5. Assembly the LSD hinges
Safety Information: LSD door kits must be installed according to the vehicle-specific instructions provided by LSD-Doors. The installation should be performed by an authorized dealer. When extending factory wire harness, follow the vehicle manufacturer's guidelines for cable repairs. When extending CAN-bus, pay attention to the processes of rerouting, screening, and twisting (check vehicle manufacturer's specifications). Be careful not to damage any systems. After installation of the kit, side airbags (if any) should be tested for proper operation by an authorized dealer. Performing final adjustments of the doors, make sure they close and lock according to the OEM specifications (check original closing angles, locking positions, gaps, etc.). Be careful while working in the operating area of the doors and hinge system (be especially careful when working with a partner or when there are other people in the working area). All doors must be securely closed before setting vehicle into motion. Driving with open doors is prohibited. Do not mount heavy loudspeakers without increasing pressure of the gas spring. Adjust horizontal opening angle of the doors to the possible maximum. The gas spring should hold your door at the maximum height under all operating conditions. To guarantee that, choose gas spring with the appropriate pressure level. Empty door storage compartments, otherwise all the objects placed in there will fall as the door opens and the weight of the door will change, which may influence the gas spring operation. WARNING: gas spring is under extreme pressure! Make sure all mounting brackets are securely fastened in the right places. General instructions: A properly instructed partner will make the installation process easier. Regular servicing of the doors and gas springs at a specialized body shop will expand their service life.! Attention! An additional inside handle must be installed to simplify opening and closing of the doors from seated position. White door lights must be disabled via removal of light bulbs or bulb sockets in accordance with Fig. 5.22 of ECE Reg. No. 48. After installation of the LSD hinge system, reinstall original inner fender cover to keep LSD hinges free from debris. Functionality of the vehicle comfort systems, e.g., central locking system (if any), must be checked at an authorized body shop. Check functionality of all other systems and components (loudspeakers, anti-theft systems, CAN-bus, window rollers, crash-sensors, driver seat memory, mirror heating/adjustment, etc.) at an authorized body shop. When adjusting the doors, be careful to place them in the proper door openings not to cause any damage to other components. The processes of adjustment and testing must be performed with great attention. If A-pillar or doors have been modified, use supplied chassis glue (if specified in the list and included in the set) for tight joint. Make sure that sealed surfaces are free from dust and grease before applying chassis glue. Proper door sealing will guarantee safety. Note: gas springs have been tested on standard doors. If your doors come with additional equipment, it may slightly modify their weight and you may need to order stronger or lighter gas spring (additional costs may arise). Please note that the gas spring pressure may vary due to temperature, which will influence opening and closing force. Warranty claims will not be honored unless there is defect in material or workmanship. When body work is performed, apply anti-corrosion covering to all the modified surfaces according to the manufacturer s guidelines. After the LSD kit installation, the doors opening angle is limited. The doors must be first carefully opened outwards and then upwards. When too much force is applied to the limiters/stop points body parts may damage. The warranty does not cover damages caused by improper use, improper installation, or application of excessive force to the limiters/stop points.
Modifying the fender Steps below are to be used as a reference. Please repeat for both fenders. Pneumatic air saw This part must be cut out A1 A3 A2
A1.) 50 mm / 2,0 inch 45 mm / 1,8 inch A2.) 160 mm / 6,3 inch
A3.) This part must be cut out carefully. Only cut through the upper sheet. Inside Inside
Hardware list (per vehicle side) 1x A 1X B 1x C 3x D 68350023 67020003 68320078 M6x20 65321350 Snap ring Cable ties Rivetting nut Washer 1x E 1x F 4x G 1x H 65321554 65321662 68320049 M8x30 1x Dick / flat Cover plate door stopper Door cover plate Serrated bolt Washer 65321523 65321315 4x I 1x J 2x K 1x L 68320044 M8x30 65321881 68310049 M6 68510041 Allen srew Gas spring Serrated nut Chassis glue 1x M 5x N 1 x O 1 x P 65210091 68320050 67020100 Spiral hose Self tapping srew Cable clip 67020900 Adhesive tape
Hardware list (per vehicle side) 1x Q 1x R Q + R 2x S 68580007 LSD swing arm LSD ground plate LSD door system Sticker 4x T 4x U 67020501 64912245 2450 N Rubber grommet Gas spring
3 I I G 4 G 5 4x 68320044 Assembly group slide roller Left 50100014 Right 50100024 A G I 1 A I G 1. MAGIC STICK - lower adjustement screw 2. M.A.R.A (Multiple - Axis - Rotational - Assembly) 3. 3rd ground plate mounting point 4. Guided Slide System (GRS) 5. Limiting adjustment screw
1.) Dismantle and cut off the fender holder on the dashed line. 1.1.) Modified fender holder
2.) Remove the cable grommet and wrap the cable with the supplied adhesive tape. 3.) Press the door stopper inside the door or dismantle the door stopper. After the disassembling close the hole with the supplied cover plate and seal it with chassis glue.
4.) Close the door extended cable harness leadthrough hole with the supplied cover plate (F), and screws (N) (required drilling: Ø 2 mm / 0,08 inches) and seal it with chassis glue (L). F T 5.) Disassemble the swing arm (Q) off the chassis plate (R). Picture only for reference Q R
6.) Mount the LSD ground plate (R) to the original hinge mounting holes /points on the chassis. Use supplied bolts (I). Additional mount the holder with the standard bolt (OEM). OEM I 7.) Close the door extended cable harness lead-through hole with the supplied cover plate (J), and screws (N) (required drilling: Ø 2 mm / 0,08 inches) and seal it with chassis glue (L). I T J Cable I I Please refer to the vehicle manufacturer for torque specifications.
8.) Now the LSD swing arm (Q) has to be installed in the original mounting points on the door with the screws (G). Fixing the swingarm in center position. G G G G Please refer to the vehicle manufacturer for torque specifications.
9.) Place the door back on the car, and close the door completely. TIP/ADVISE: Use the lower adjustment screw, MAGIC STICK (1) as a point to guide the front of door in the correct position. 10.) Attach the swing arm to the ground plate with the 4 included bolts and adjust the door via moving the swing arm to chassis plate adjustable (2) connection mount with horizontal door gap adjuster (2) in the right or left direction until gap measurement is like original. On completion: tightening torque 20 ft - lb (27Nm). 11.) Position the lower adjustment screw, MAGIC STICK (1) in that way, which the door closes in the center position. On completion: tightening torque 10 ft - lb (14 Nm).
12.) Adjust the height of the door by moving the ground plate (R) vertically. You might have to loosen bolts (I) on the ground plate to do this. Adjust the depth of the door by moving the swing arm (Q) horizontal. You might have to loosen the bolt (G) on the swing arm to do this. 10.) Only if required and if available Carefully reopen the door and adjust the opening angle with the limiting adjustment screw (5). Consider the fender distance. Then lock adjustment screw (5) again. Important: When you adjust screw (5) you also have to readjust slide roller (4). They need to be adjusted that the LSD swing arm has slight tension at pivoting. 5
14.) Hang in the gas spring (U) on the fitting point of the swing arm. Secure it with the supplied security ring, by means of needlenosed pliers. Use the security ring carefully. Do not overstretch the security ring The signification on the gas spring must be visible 15.) Carefully pivot the door up, place in the gas spring (U) on the according mounting point on the chassis plate. Secure it with the supplied security ring. Danger: Gas spring is under extreme pressure! Please make sure the security rings are installed correctly and are snapped their respective guides.
16.) Only if required If the Magic Stick - lower adjustment screw (1) is not in correct position when the door is closed, spacer (D) has to be installed under the M.A.R.A. (2) as shown. For this opening the door up! 1 1 2 D D 2 2 D 2 D
17.) Please adjust the slide roller (4) so the LSD swing arm has initial contact and preload while opening and closing. Use a spacer (s) if applicable (H). Please lubricate the slide roller (4) with grease from time to time. 4 Washer Washer
18.) Close the door again and let the door lock and set in place. 19.) After adjustments are finalized, tighten the standard and the marked screw. 20.) Now reassemble the previously modified fender back on the car to see if there are any obstructions. 21.) Pivot the door carefully up and make sure there is sufficient clearance on the fender, A-pillar and hood. If necessary adjust the LSD chassis plate or the LSD swing arm again. 22.) Remove the fender again and close the door
23.) Lay the wire harness on and attach it to the marked points, then secure with included cable ties (B). Addtitional wrap the cabel with the supplied spiral hose (M). B M Lay the cable under the hinge 24.) Now reassemble the modified fender back on the car.